Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01C—RESISTORS
  • H01C7/00—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material
  • H01C7/02—Non-adjustable resistors formed as one or more layers or coatings; Non-adjustable resistors made from powdered conducting material or powdered semi-conducting material with or without insulating material having positive temperature coefficient
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01C—RESISTORS
  • H01C1/00—Details
  • H01C1/14—Terminals or tapping points or electrodes specially adapted for resistors; Arrangements of terminals or tapping points or electrodes on resistors
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01C—RESISTORS
  • H01C1/00—Details
  • H01C1/14—Terminals or tapping points or electrodes specially adapted for resistors; Arrangements of terminals or tapping points or electrodes on resistors
  • H01C1/1406—Terminals or electrodes formed on resistive elements having positive temperature coefficient

Definitions

• the present invention relates to a PTC element and a starter circuit for a fluorescent lamp incorporating the PTC element.
• the "PTC element” refers to a thermistor having a positive temperature coefficient (Positive Temperature Coefficient), as is known in the field of electric and electronic circuit technology. PTC elements are relatively low! Their electrical resistance (or impedance) is low under temperature conditions (for example, at room temperature), but their electrical resistance rises sharply above a certain temperature (hereinafter referred to as the trip temperature). Add. In the present specification, the former state of the PTC element is also referred to as a low state, and the latter state is referred to as a high state.
• a starter circuit for an inverter-type fluorescent lamp uses a ceramic PTC element and a capacitor connected in parallel with the fluorescent lamp, respectively (for example, refer to Patent Document 1).
• FIG. 5 shows a typical electric circuit diagram (including a conventional starter circuit) of an inverter-type fluorescent lamp device.
• a conventional starter circuit 60 (referred to as a portion surrounded by a dotted line in FIG. 5) is configured such that a PTC element 61 and a start capacitor 63 are connected in parallel with a fluorescent lamp 65, respectively.
• the fluorescent lamp 65 is connected to an inverter circuit (details are omitted) 70 via a coil 67 and a capacitor 69.
• Such an inverter-type fluorescent lamp device is turned on as follows. First, an AC power supply (not shown) is turned on, and a high-frequency current flows through the electric circuit shown in FIG. Since the PTC element 61 is initially in the low state and has a low impedance, most of the current flowing through the filament of the fluorescent lamp 65 flows through the PTC element 61, and the filament of the fluorescent lamp 65 and the PTC element 61 have their joules. Heated by heat. Eventually, when the PTC element 61 trips to a high state due to its own Joule heat, the impedance of the PTC element 61 increases significantly.
• thermoelectrons are emitted from the lamp and the fluorescent lamp is turned on. Even after the PTC element 61 functions as a starter circuit as described above, the PTC element 61 is kept in the high state as long as the fluorescent lamp is lit.
• Patent Document 1 JP-A-7-161483
• a ceramic PTC element 61 is used in the conventional fluorescent lamp starter circuit 60 as described above.
• a ceramic PTC element (CPTC element) is generally formed by sandwiching a main body made of a ceramic material such as an oxide semiconductor mainly composed of, for example, norium titanate between electrodes. It is well known that a ceramic PTC element has a capacitance component in the element itself, so that the electric characteristics for passing an alternating current change. For this reason, there is a problem that the intended electrical characteristics cannot be obtained in the device using the AC power supply.
• One object of the present invention is to provide a novel fluorescent lamp starter circuit that solves the above-mentioned problems.
• Another object of the present invention is to provide a PTC element having a novel structure suitable for use in such a fluorescent lamp starter circuit. Means for solving the problem
• CPTC elements ceramic PTC elements
• PPTC devices polymer PTC devices
• the present inventors focused on the polymer PTC device, and similarly examined the electrical characteristics of the polymer PTC device.
• the ceramic PTC element exhibited remarkably different electric characteristics from those when a direct current was applied, and that the electric characteristics also changed depending on the frequency of the alternating current.
• the change in electrical characteristics was not seen as much as in the ceramic PTC element.
• the impedance in the high state is significantly reduced to 1 ⁇ 10 4 ⁇ or less, whereas in the polymer PTC element, a high ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ ⁇ impedance of 1 ⁇ 10 5 ⁇ or more is obtained. (At a frequency of about 70 kHz). This is considered to be because the ceramic PTC element has a capacitance component, whereas the polymer PTC element has almost no capacitance component.
• a fluorescent lamp starter circuit including a polymer PTC element (more specifically, an inverter-type fluorescent lamp starter circuit) is provided.
• a starter circuit can be configured such that, for example, a polymer PTC element and a capacitor are respectively connected in parallel with a fluorescent lamp.
• the frequency dependence of electrical characteristics is higher than that of a conventional starter circuit using a ceramic PTC element. Higher impedance is obtained in the low state with high performance.
• the power consumption by the starter circuit in the lighting state meaning while the fluorescent lamp is actually lit, and not including the initial state from when the power is turned on to when the fluorescent lamp is lit
• Such a fluorescent lamp starter circuit of the present invention does not require additional components such as a rectifying element, does not substantially increase the occupied space, and is applicable to existing fluorescent lamp manufacturing equipment and methods. is there.
• a polymer P comprising a sheet-like body also comprising a polymer PTC material, and first and second electrodes formed on the surface of the sheet-like body.
• a PTC element more specifically, a polymer PTC element, which is a TC element, and is provided with a space at least partially crossing the sheet-shaped body in a thickness direction.
• the withstand voltage characteristics can be improved as compared with the conventional polymer PTC device.
• the withstand voltage characteristic is defined as the time until the PTC element breaks down when the power is turned on and when the PTC element breaks down when the power supply is repeatedly turned on and off. Say the number of iterations.
• the withstand voltage characteristics of the former is that the PTC element is incorporated into the fluorescent lamp device, the power is turned on and the fluorescent lamp is turned on.
• the peak voltage is lkV, and then the voltage of about 50 to 150 V is applied to the PTC element. It means the time until the PTC element breaks down when it is turned on when it is maintained under such voltage conditions as apply to it.
• the withstand voltage characteristics of the latter are as follows: With the PTC element incorporated in the fluorescent lamp device, the power is turned on and off for a predetermined time, the fluorescent lamp is turned on and turned off under the same voltage conditions as above, and this is defined as one cycle. When repeated, it refers to the repetition cycle until the PTC element fails.
• the space may be at least partially defined by an inner wall surface of a through hole passing through the sheet-shaped body.
• the above space may be the entire through-hole, or if there is an insert such as a terminal in the through-hole, the above space may be inside the through-hole. It may be a gap defined between the wall surface and the insert.
• the space may be a recess provided halfway through the sheet-shaped main body. The position, shape, size, and the like of this space can be appropriately selected in consideration of the relationship with the electrodes and terminals as described later, preferably so as not to substantially affect the electrical characteristics of the PTC element.
• the number of spaces is not particularly limited, and it is sufficient that at least one space is provided. However, two or more spaces are preferably provided so that thermal expansion and thermal stress can be efficiently absorbed.
• the first and second electrodes of the PTC element are the same on the sheet-like body. It is formed spaced apart on the sheet surface. According to such a configuration, even if a failure should occur, the failure occurs in the open mode without a short circuit, and fail-safe can be realized, thereby improving safety. This is considered to be because fatigue due to repeated thermal stress concentrates on the portion of the sheet-shaped main body located near the outer edge of the electrode, and in the case of failure, the element is easily broken at that portion.
• the distance between the first and second electrodes is preferably equal to or greater than the thickness of the sheet-shaped main body. By taking such a distance, in the unlikely event of a failure, the open mode can be given higher priority.
• the first and second electrodes of the PTC element are formed so that they do not overlap each other when projected and viewed in the vertical direction (the thickness direction of the sheet-shaped body). Each is formed on a pair of opposing sheet surfaces of the body. According to such an embodiment, the same effect as the above-described embodiment can be obtained. For the same reason, the distance between the first and second electrodes when projected and viewed is equal to or greater than the thickness of the sheet-shaped main body. It is preferable that
• the invention is not limited to this, and the first and second electrodes of the PTC element can be arranged in any suitable relationship.
• three or more electrodes may be provided as long as there are at least two types of electrodes having different potentials.
• first, third or more electrodes may be provided in parallel on the same sheet surface of the PTC element, or may be alternately provided in parallel on opposite sheet surfaces of the PTC element.
• the terminals can be fixed to the electrodes by, for example, soldering.
• the space is projected inside in the vertical direction (the thickness direction of the sheet-shaped main body) and inside the region surrounded by the outer edge of the electrode, preferably the operating portion. Can be provided at a position close to the vehicle.
• the transverse cross section of the space is smaller than the area surrounded by the outer edges of the electrodes.
• the relationship between the space and the terminal is not particularly limited.
• the terminal may be inserted through the space so as to leave a gap between the contour and the terminal, or may be inserted partway into the space.
• the space and the terminal may be adjacent to each other so that the opening of the space is closed at the end of the terminal.
• the terminal is inserted into the wall defining the space until the contour of the wall defining the space is substantially the same as the lateral cross section of the terminal.
• the “sheet shape” refers to a sheet having a substantially rectangular cross section, a Z or a layer, and the like.
• a “sheet-shaped body” is one in which a pair of opposing sides of a substantially rectangular cross section is considerably larger than another pair of opposing sides, or is cut out from such an object. Good. In the latter case, in the substantially rectangular cross section of the “sheet-shaped body”, one pair of opposing sides may not necessarily be considerably larger than the other pair of opposing sides.
• the “sheet surface” refers to a surface including a longer side and sides of a substantially rectangular cross section of the sheet-shaped main body.
• the “longitudinal direction” means the thickness direction of the sheet-shaped main body
• the “lateral direction” means the direction along the sheet surface.
• the PTC element of the present invention as described above frequently trips between the low state and the high state, and is suitable for applications in which expansion and contraction due to heat are repeated. Therefore, the PTC element of the present invention can be suitably incorporated in the fluorescent lamp starter circuit of the present invention, more specifically, the inverter type fluorescent lamp starter circuit. In addition to the fluorescent lamp starter circuit, for example, it can be suitably used for a startup circuit that is connected to an AC power supply and requires a large current only at the time of startup.
• the present invention is not limited to this, and that the PTC device of the present invention can be used in other applications where thermal expansion and contraction are problematic.
• the fluorescent lamp starter circuit of the present invention uses a polymer PTC element, the frequency dependence of the electrical characteristics of the fluorescent PTC element is lower than in the case of using a ceramic PTC element. The power can be reduced.
• a PTC element suitable for use in a fluorescent lamp starter circuit.
• the sheet-shaped main body is at least partially Since the space that crosses the PTC element can absorb the thermal expansion and z or thermal stress generated in the sheet-shaped body, the withstand voltage characteristics can be improved as compared with the polymer PTC element having the conventional structure.
• FIG. 1 is a diagram schematically illustrating a polymer PTC element according to one embodiment of the present invention, wherein FIG. 1 (a) is a cross-sectional view, and FIG. FIG. 1C is a cross-sectional view taken along the line A ′, and FIG. 1C is a cross-sectional view at the time of failure corresponding to FIG. 1A.
• FIG. 2 (a) and (b) are schematic cross-sectional views of a polymer PTC element in various embodiments of the present invention.
• FIG. 3 is a graph showing resistance-temperature characteristics (DC) of a PTC element, where FIG. 3 (a) shows a case of a polymer PTC element and FIG. 3 (b) shows a case of a ceramic PTC element.
• DC resistance-temperature characteristics
• FIG. 4 is a graph showing the impedance-temperature characteristic (AC) of the PTC element.
• FIG. 4 (a) shows the case of the polymer PTC element
• FIG. 4 (b) shows the case of the ceramic PTC element.
• FIG. 5 is an electric circuit diagram including a conventional starter circuit of the inverter-type fluorescent lamp device.
• FIG. 6 is a diagram schematically illustrating one type of conventional polymer PTC element, in which FIG. 6 (a) is a cross-sectional view and FIG. 6 (b) is a top view.
• FIG. 7 is a diagram schematically illustrating another conventional type of polymer PTC element.
• FIG. 7 (a) is a cross-sectional view
• FIG. 7 (b) is a cross-section at the time of failure corresponding to FIG. 7 (a).
• FIG. 7 (a) is a cross-sectional view
• FIG. 7 (b) is a cross-section at the time of failure corresponding to FIG. 7 (a).
• the polymer PTC element 10 of the present embodiment has a metal part 3a and a metal part 3a on one of a pair of opposite sheet surfaces of the sheet-shaped main body 1 which also has a polymer PTC material force. 3b is formed, and metal portions 4a and 4b are formed on the other surface. These metal parts 3a and 3b are arranged on the same sheet surface, preferably at a distance greater than the thickness of the sheet-shaped main body 1, and the same is true for the metal parts 4a and 4b.
• a through hole 7a is provided through the sheet-shaped body 1 and the metal parts 3a and 4a
• a through-hole 7b is also provided through the sheet-shaped body 1 and the metal parts 3b and 4b.
• a space (or gap) is left between the terminals 5a and 5b and the inner wall surfaces of the through holes 7a and 7b.
• the terminals 5a and 5b extend in the vertical direction from one sheet surface side of the sheet-shaped main body 1 through the inside of the through holes 7a and 7b, and protrude from the opposite sheet surface side.
• the terminal 5a is fixed to the metal parts 3a and 4a by solder joints 9a and 9a ', respectively
• the terminal 5b is fixed to the metal parts 3b and 4b by solder joints 9b and 9b', respectively.
• the metal portions 3a and 4a function as first electrodes having the same potential
• the metal portions 3b and 4b function as second electrodes having the same potential.
• the sheet-shaped body 1 has a rectangular parallelepiped shape of about 3 mm in length, about 11 mm in width, and about lmm in thickness, and the metal parts 3a, 3b, 4a, 4b are about 3 mm in length, about 3 mm in width, and about 3 mm in thickness. It may have a 0.03 mm rectangular parallelepiped shape.
• the through holes 7a and 7b may have a cylindrical shape with a diameter of about 0.8 mm, and the terminals 5a and 5b may have a cylindrical shape with a diameter of about 0.7 mm.
• the through-holes 7a and 7b are located at the center of the area surrounded by the outer edges of the metal parts 3a and 4a and 3b and 3b in view of the longitudinal force. In this case, it is considered preferable to be closer to the center of the sheet-shaped body 1).
• the size, shape, and the like of each member can be appropriately selected by those skilled in the art.
• the polymer PTC element 10 can be manufactured as follows. First, a sheet-shaped polymer PTC material is prepared. As the polymer PTC material, for example, a material in which conductive particles such as carbon black are dispersed in a polymer material such as polyethylene can be used. A metal foil such as a Cu foil is applied to both of the pair of sheet surfaces, and the metal foil is plated with Ni or the like as necessary. The sheet thus obtained is cut with a drill to form through holes 7a and 7b. Drilling is preferably performed before etching because the mechanical strength of the element is improved.
• a sheet-shaped polymer PTC material is prepared.
• the polymer PTC material for example, a material in which conductive particles such as carbon black are dispersed in a polymer material such as polyethylene can be used.
• a metal foil such as a Cu foil is applied to both of the pair of sheet surfaces, and the metal foil is plated with Ni or the like as necessary.
• the sheet thus obtained is cut with a drill to form through holes
• the metal foil (possibly with a plating) is etched in a predetermined pattern to form metal portions 3a, 3b and 4a, 4b, and cut into chips of a predetermined size.
• the general terminals 5a and 5b which also have a metal force such as Cu (or may have a plating), are fixedly connected to the metal portions 3a and 3b by, for example, soldering.
• the polymer PTC element 10 is obtained.
• the polymer PTC element 10 can be generally coated with, for example, silicone resin.
• electrodes 83a and 83b are provided on one sheet surface of a sheet-shaped main body 81 made of a polymer PTC material, as shown in FIGS. 6 (a) and 6 (b).
• a polymer PTC element 80 in which terminals 85a and 85b, which are spaced apart and are fixed at solder joints 89a and 89b, also extend in parallel with the forces of the electrodes 83a and 83b, respectively, in the lateral direction.
• terminals 85a and 85b which are spaced apart and are fixed at solder joints 89a and 89b, also extend in parallel with the forces of the electrodes 83a and 83b, respectively, in the lateral direction.
• the thermal expansion due to the space between the inner wall surfaces of the through holes 7a, 7b provided in the sheet-shaped main body 1 and the terminals 5a, 5b ( In Fig. 1 (a), the direction of expansion is schematically indicated by an arrow for the purpose of easy understanding), and thermal stress can be reduced. As a result, the life until failure can be extended, and the withstand voltage characteristics are improved.
• FIG. 7A As another type of conventional polymer PTC element, as shown in FIG. 7A, a sheet-shaped main body 91 made of a polymer PTC material is sandwiched between electrodes 93a and 93b. Force terminals 95a and 95b extend laterally in opposite directions! Polymer PTC elements 90 are known. If such a conventional polymer PTC element 90 should fail due to an accidental external factor (for example, mechanical contact), a mode as shown in FIG. 7B may occur.
• an accidental external factor for example, mechanical contact
• the polymer PTC element 10 of the present embodiment fails in the open mode due to the occurrence of cracks near the electrodes as shown in FIG. Therefore, safety is improved as compared with the conventional polymer PTC element 90 as described above.
• the difference in heat distribution and heat dissipation inside the sheet-like body 1 and the metal parts 3a, 4a, 3b, 4b made of a metal material with the sheet-like body 1 Of various factors such as the difference in the coefficient of thermal expansion between the metal parts 3a, 4a, 3b, and 4b, especially the sheet-like body 1 located near the outer edge B on the element center side. It is considered that the fatigue caused by thermal stress concentrates on the part, and in the event of a failure, priority is given to running the partial force crack and destroying the element.
• At least one of the metal parts 3a, 3b, 4a and 4b is formed with a notch in a part of the sheet-shaped main body located near the outer edge on the element center side. Just a little.
• the force described for the PTC element of the present invention in one embodiment is not limited to this, and it will be readily apparent to those skilled in the art that various modifications can be made without departing from the concept of the present invention. Will be appreciated.
• the metal parts 4a and 4b are provided, and the solder parts 9a ′ and 9b ′ are joined to the terminals 5a and 5b at the metal parts 4a and 4b and the solder parts 9a ′ and 9b ′. May be omitted.
• terminals 5a and 5b may be connected to metal parts 4a and 3b, respectively.
• the metal parts 4a and 3b function as electrodes.
• These metal parts 4a and 3b are formed on the opposing sheet surfaces of the sheet-shaped main body 1 so as not to overlap each other when projected in the vertical direction.
• the space is provided in the form of a gap between the through hole and the terminal.
• the terminal may not be inserted in the through hole, and the entire through hole may be a space. Further, even if a space is provided in the form of a concave portion that reaches halfway in the sheet-shaped main body, thermal expansion may be absorbed.
• This embodiment relates to a fluorescent lamp starter circuit using a polymer PTC element.
• the fluorescent lamp starter circuit (not shown) of the present embodiment is different from the conventional starter circuit of the inverter type fluorescent lamp device shown in FIG. 5 in that the polymer PTC element 10 of the first embodiment is replaced with the ceramic PTC element 61. It is composed of
• the starter circuit for a fluorescent lamp according to the present embodiment obtained in this way has a lower frequency dependence of the electrical characteristics than the conventional starter circuit for a fluorescent lamp using the ceramic PTC element 61. Power consumption by the circuit can be reduced.
• the polymer PTC element of the first embodiment is used in the present embodiment, as described above in the first embodiment, in the conventional starter circuit for a fluorescent lamp, instead of the ceramic PTC element, there is an advantage in that high voltage resistance and high safety can be obtained as compared with the case where a known polymer PTC element is applied.
• the polymer PTC element of Embodiment 1 is used, but the polymer PTC element of the present invention in another aspect may be used. Also, a polymer PTC element known in the art may be used.In this case, the frequency dependence of the electrical characteristics is lower than that of a conventional fluorescent lamp starter circuit using a ceramic PTC element. There is an effect that power consumption by the starter circuit in the state can be reduced.
• the electrical characteristics of the polymer PTC device of the present invention were examined. Note that the resistance or impedance of the PTC element In all cases, the impedance was measured after maintaining the device for 15 minutes under a predetermined temperature condition in the range of 20 to 160 ° C. The value of this temperature condition may be regarded as the temperature of the force PTC element itself, which is the ambient temperature of the PTC element.
• a polymer PTC element of Embodiment 1 was produced.
• a ceramic PTC element was obtained commercially.
• the resistance-temperature characteristics of the element were measured by measuring the resistance value of the element alone in the case of direct current under various temperature conditions using a general DC resistance meter. Examined. The results are shown in Fig. 3 (a) and (b).
• the impedance value in the case of alternating current in the state of the element alone under various temperature conditions was measured using a general LCR meter.
• the impedance-temperature characteristics of the device were examined.
• the AC frequency was changed to 20 kHz, 50 kHz and 70 kHz, and the resistance value was measured for each frequency.
• the results are shown in FIGS. 4 (a) and (b).
• the polymer PTC element (Fig. 4 (a)) has a lower high state in the low state than the ceramic PTC element (Fig. 4b).
• the state showed a higher impedance, a larger impedance difference and a steeper impedance change.
• the high state impedance is less than 1 ⁇ 10 4 ⁇ for a ceramic PTC element, whereas it is 1 ⁇ 10 4 for a polymer PTC element.
• the polymer PTC element of the example higher impedance can be obtained in the high state as compared with the ceramic PTC element of the comparative example. A reduction in power consumption by the starter circuit in the lighting state can be expected.
• a lower impedance can be obtained in the low state compared to the ceramic PTC element of the comparative example. The heating of the filament can be performed more efficiently, and the time required for turning on the power supply and turning on the fluorescent lamp can be reduced.
• the impedance in the high state generally decreases as the frequency increases in the ceramic PTC device of the comparative example, but the impedance of the polymer of the example increases.
• the temperature decreased as the frequency increased in the temperature range higher than about 110 ° C, but showed a high value in the temperature range of about 110 ° C or less, almost independent of the frequency.
• the electrical characteristics of a fluorescent lamp starter circuit using the polymer PTC element of the present invention were examined.
• the initial impedance value was measured in advance as a guide to the characteristics of the PTC element used (see Table 1).
• the initial impedance was measured using the same LCR meter used above to examine the device characteristics, with the device alone (room temperature (about 25 ° C), frequency 1 kHz).
• a fluorescent lamp starter circuit of the second embodiment was manufactured using the polymer PTC element of the example whose element characteristics were examined above.
• the fluorescent lamp a commercially available light bulb type inverter fluorescent lamp was used.
• a general AC ammeter is inserted at the point X, and a general AC voltmeter is connected to the point Y-Y 'to supply a high-frequency AC current, thereby turning on the fluorescent lamp.
• the current and voltage of the PTC element were measured.
• a starter circuit for a fluorescent lamp was manufactured in the same manner using the ceramic PTC element of the above comparative example, and the starter circuit of this comparative example was similarly manufactured. Tested. Table 1 shows the results. Note that the measured values of current and voltage in Table 1 are effective values.
• the starter circuit of the comparative example leaks current to the ceramic PTC element when the fluorescent lamp is lit, whereas the starter circuit of the embodiment shows the polymer leaked. It is presumed that relatively little current flows through the PTC element, and the power consumption of the starter circuit in the lighting state can be reduced.
• the polymer PTC device of the present invention can be used as a switching device in the field of electric and electronic technology.
• the fluorescent lamp starter circuit of the present invention can be suitably used particularly as an inverter type fluorescent lamp starter circuit.

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• 2004
  • 2004-10-20 JP JP2005514836A patent/JPWO2005038826A1/ja active Pending
  • 2004-10-20 CN CNA2004800311344A patent/CN1871669A/zh active Pending
  • 2004-10-20 EP EP04792635A patent/EP1686596A4/en not_active Withdrawn
  • 2004-10-20 KR KR1020067009774A patent/KR20060127854A/ko not_active Application Discontinuation
  • 2004-10-20 TW TW093131776A patent/TW200520627A/zh unknown
  • 2004-10-20 WO PCT/JP2004/015469 patent/WO2005038826A1/ja active Application Filing
  • 2004-10-20 US US10/576,629 patent/US20070170831A1/en not_active Abandoned

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